Porous Membrane Polymeric Features Nanoscale Injection Molding
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Solution Overview
Problem
Traditional methods for manufacturing porous membranes, such as lamination, often result in defects, distortions, and incomplete sealing, which reduce the membrane's effectiveness and introduce impurities, especially when using spacers that block the membrane's surface area and complicate the filtration process.
Innovation Solution
The integration of polymeric features onto the surface of porous membranes using nanoscale injecting molding, allowing for precise control over the shape, configuration, and placement of these features to enhance flow paths, cleanliness, and functionality, while minimizing the impact of spacers and improving lamination processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional lamination methods are used to bond membrane layers, then the membrane layers can be joined together, but the process causes defects, distortions, and delamination over time
Solution Approach 1:
The patent changes the bonding parameters by using a single heating event at controlled temperature and pressure, rather than repeated heating cycles. This prevents thermal distortion of the porous structure while achieving sufficient bonding strength through optimized heating parameters that avoid delamination.
Solution Approach 2:
The patent applies preliminary surface treatment to the membrane layers before lamination to enhance bonding without requiring repeated heating. This preliminary preparation ensures reliable bonding from the first heating event, preventing subsequent delamination while avoiding distortions from multiple thermal cycles.
2Ease of operation
If screens or spacers are placed between membrane pleats to maintain separation, then the pleats remain separated for optimized flow, but the screens block substantial membrane surface area and reduce filtration efficiency
Solution Approach 1:
The patent extracts and removes the screen or spacer component entirely from the system. Instead of placing screens between pleats, the invention uses the pleated membrane structure itself with controlled spacing to maintain separation while maximizing active filtration surface area, thereby eliminating the trade-off between flow optimization and filtration efficiency.
3Strength
If thicker spacers are used to maintain pleat separation, then the structural support is improved, but the amount of membrane that can be packed into the housing is reduced
Solution Approach 1:
The patent uses thin film structures with inherent flexibility to provide the necessary pleat separation and structural support. The flexible thin films maintain pleat spacing through their mechanical properties rather than requiring thick rigid spacers, thereby maximizing the membrane packing area within the housing while maintaining structural integrity.
4Ease of manufacture
If traditional extruded sheets or fiber nets are used for spacers, then the manufacturing is simplified, but the thickness of 50 microns or greater reduces membrane packing density
Solution Approach 1:
The patent replaces traditional thick extruded sheets and fiber nets with thin film structures that can be manufactured with simplified processes. These thin films provide the necessary spacer function at minimal thickness, maintaining ease of manufacture while dramatically increasing membrane packing density through reduced non-filtration material.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables improved flow efficiency, reduced pressure drop, and enhanced filtration performance by optimizing the membrane's surface area utilization and minimizing distortions, leading to cleaner filtration results with reduced impurities and increased membrane durability.
Implementation Method 1
bonding the material of the polymeric feature to a material used for the porous membrane via a molecular inter-reaction
Data Source
AI summary
The disclosure describes a porous membrane including the following: at least one polymeric feature on a surface of a porous membrane wherein the at least one polymeric features are bonded to the membrane using a nanoscale injecting molding device. Another aspect of the disclosure includes a porous membrane including the following: a first film layer; a second film layer; at least one polymeric feature between the first film layer and second film layer, wherein the at least one polymeric feature is bonded to at least the first film layer.